Composite ultrasonic material applicators with individually addressable micro-applicators and methods of use thereof

ABSTRACT

A material applicator for controlling application of at least one material on a substrate includes a housing and an array plate with an applicator array positioned within the housing. The applicator array has a plurality of micro-applicators and each of the plurality of micro-applicators has an ultrasonic transducer, a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures. The applicator plate is in mechanical communication with the ultrasonic transducer such that at least one material is ejected through the plurality of apertures as atomized droplets when the ultrasonic transducer vibrates the micro-applicator plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to the benefit of U.S. application Ser.No. 16/211,554, filed Dec. 6, 2018, which claims the benefit of U.S.provisional application No. 62/624,013 filed on Jan. 30, 2018. Thedisclosures of the above applications are incorporated herein byreference

FIELD

The present invention relates to the painting of vehicles, and moreparticularly to methods and equipment used in high volume production topaint the vehicles and components thereof.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Painting automotive vehicles in a high volume production environmentinvolves substantial capital cost, not only for application and controlof the paint, but also for equipment to capture overspray. The overspraycan be up to 40% of the paint that exits an applicator, or in otherwords, to 40% of the paint that is purchased and applied is wasted (i.e.the transfer efficiency is ˜60%). Equipment that captures oversprayinvolves significant capital expenses when a paint shop is constructed,including large air handling systems to carry overspray down through apaint booth, construction of a continuous stream of water that flowsunder a floor of the paint booth to capture the overspray, filtrationsystems, and abatement, among others. In addition, costs to operate theequipment is high because air (flowing at greater than 200K CFM) thatflows through the paint booths must be conditioned, the flow of watermust be maintained, compressed air must be supplied, and complexelectrostatics are employed to improve transfer efficiency.

With known production equipment, paint is atomized by rotating bells,which are essentially a rotating disk or bowl that spins at about20,000-80,000 rpms. The paint is typically ejected from an annular sloton a face of the rotating disk and is transported to the edges of thebell via centrifugal force. The paint then forms ligaments, which thenbreak into droplets at the edge of the bell. Although this equipmentworks for its intended purpose, various issues arise as a result of itsdesign. First, the momentum of the paint is mostly lateral, meaning itis moving off of the edge of the bell rather than towards the vehicle.To compensate for this movement, shaping air is applied that redirectsthe paint droplets towards the vehicle. In addition, electrostatics areused to steer the droplets towards the vehicle. The droplets have afairly wide size distribution, which can cause appearance issues.

These issues of overspray, transfer efficiency, and paint uniformity,among other issues related to the painting of automotive vehicles orother objects in a high volume production environment, are addressed bythe present disclosure.

SUMMARY

In one form of the present disclosure, a material applicator forcontrolling application of at least one material on a substrate includesa housing and an array plate with an applicator array positioned withinthe housing. The applicator array has a plurality of micro-applicatorsand each of the plurality of micro-applicators has an ultrasonictransducer, a material inlet, a reservoir, and a micro-applicator platewith a plurality of apertures. The applicator plate is in mechanicalcommunication with the ultrasonic transducer such that at least onematerial is ejected through the plurality of apertures as atomizeddroplets when the ultrasonic transducer vibrates the micro-applicatorplate.

In some variations, each of the plurality of micro-applicators includesa frame with the reservoir positioned between the frame and themicro-applicator plate. In such variations, the frame can have a backwall and at least one sidewall and the reservoir can be between the backwall and the micro-applicator plate. Also, in at least one variation theultrasonic transducer is positioned between the frame and themicro-applicator plate.

In some variations, at least a subset of the plurality ofmicro-applicators is individually addressable to apply the at least onematerial to the substrate. And in at least one variation a controllerconfigured to individually address the at least a subset of theplurality of micro-applicators is included.

In some variations, the plurality of micro-applicators are aligned on asingle plane.

In at least one variation, the plurality of micro-applicators includes afirst subset of micro-applicators arranged on a first plane and a secondsubset of micro-applicators arranged on a second plane parallel to anddifferent to the first plane. In other variations, the plurality ofmicro-applicators includes a first subset of micro-applicators arrangedon a first plane and a second subset of micro-applicators arranged on asecond plane non-parallel to the first plane. And in some variations, acontroller configured to individually address the first subset ofmicro-applicators and the second subset of micro-applicators isincluded.

In at least one variation, the material applicator further includes arobotic arm configured to move the plurality of micro-applicators acrossa surface.

In another form of the present disclosure, a material applicator forcontrolling application of at least one material on a substrate includesa housing attached to a robotic arm that is configured to move thehousing across a surface and an array plate with an applicator arraypositioned within the housing. The applicator array comprises aplurality of micro-applicators and each of the plurality ofmicro-applicators has an ultrasonic transducer, a material inlet, areservoir, and a micro-applicator plate with a plurality of apertures.The applicator plate is in mechanical communication with the ultrasonictransducer such that at least one material is ejected through theplurality of apertures as atomized droplets when the ultrasonictransducer vibrates the micro-applicator plate.

In some variations, each of the plurality of micro-applicators furthercomprises a frame with a back wall and at least one sidewall, and thereservoir is between the back wall and the micro-applicator plate. In atleast one variation, the ultrasonic transducer is positioned between theframe and the micro-applicator plate.

In some variations, the plurality of micro-applicators includes a firstsubset of micro-applicators arranged on a first plane and a secondsubset of micro-applicators arranged on a second plane parallel to anddifferent to the first plane. In other variations, the plurality ofmicro-applicators comprises a first subset of micro-applicators arrangedon a first plane and a second subset of micro-applicators arranged on asecond plane non-parallel to the first plane. And in at least onevariation a controller is included and configured to individuallyaddress the first subset of micro-applicators and the second subset ofmicro-applicators.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 is a planar view of an exemplary paint spray system according tothe teachings of the present disclosure;

FIG. 2A schematically depicts an exemplary view of an array ofmicro-applicators according to the teachings of the present disclosure;

FIG. 2B schematically depicts a side cross-sectional view of section2B-2B in FIG. 2A;

FIG. 2C schematically depicts a side cross-sectional view of section2C-2C in FIG. 2A;

FIG. 3A schematically depicts an exemplary view of an array ofmicro-applicators according to the teachings of the present disclosure;

FIG. 3B schematically depicts a side cross-sectional view of section3B-3B in FIG. 3A;

FIG. 3C schematically depicts a side cross-sectional view of section3C-3C in FIG. 3A; and

FIG. 4 is a flow diagram illustrating a method of controllingapplication of at least one material to a substrate according to theteachings of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.Examples are provided to fully convey the scope of the disclosure tothose who are skilled in the art. Numerous specific details are setforth such as types of specific components, devices, and methods, toprovide a thorough understanding of variations of the presentdisclosure. It will be apparent to those skilled in the art thatspecific details need not be employed and that the examples providedherein, may include alternative embodiments and are not intended tolimit the scope of the disclosure. In some examples, well-knownprocesses, well-known device structures, and well-known technologies arenot described in detail.

The present disclosure provides a variety of devices, methods, andsystems for controlling the application of paint to automotive vehiclesin a high production environment, which reduce overspray and increasetransfer efficiency of the paint. It should be understood that thereference to automotive vehicles is merely exemplary and that otherobjects that are painted, such as industrial equipment and appliances,among others, may also be painted in accordance with the teachings ofthe present disclosure. Further, the use of “paint” or “painting” shouldnot be construed as limiting the present disclosure, and thus othermaterials such as coatings, primers, sealants, cleaning solvents, amongothers, are to be understood as falling within the scope of the presentdisclosure.

Generally, the teachings of the present disclosure are based on adroplet spray generation device in which a perforate membrane is drivenby a piezoelectric transducer. This device and variations thereof aredescribed in U.S. Pat. Nos. 6,394,363, 7,550,897, 7,977,849, 8,317,299,8,191,982, 9,156,049, 7,976,135, 9,452,442, and U.S. PublishedApplication Nos. 2014/0110500, 2016/0228902, and 2016/0158789, which areincorporated herein by reference in their entirety.

Referring now to FIG. 1, a paint spray system 1 for painting a part Pusing a robotic arms 4 is schematically depicted. The robotic arm 4 iscoupled to at least one material applicator 10 and a rack 5. A materialsource 8 (e.g., a paint source) is included and includes at least onematerial M (materials M₁, M₂, M₃, . . . M_(n) shown in FIG. 1; alsoreferred to herein simply as “material M” or “material(S)”). In someaspects of the present disclosure the material M includes differentpaint materials, different adhesive materials, different sealantmaterials, and the like. The arm 4 moves according to xyz coordinateswith respect to rack 5 such that the material applicator 10 moves acrossa surface (not labeled) of the part P. Also, a power source 6 isconfigured to supply power to arm 4 and rack 5. Arm 4 and rack 5 areconfigured to supply material M from the material source 8 to thematerial applicator 10 such a coating is applied to the surface of thepart P. While FIG. 1 schematically depicts the paint spray system 1having a single robotic arm 4, it should be understood that paint spraysystems with more than one robotic arm 4 are included within theteachings of the present disclosure.

Referring now to FIGS. 2A through 2C, the material applicator 10according to the teachings of the present disclosure is schematicallyshown. In one form of the present disclosure, the material applicator 10includes an array plate 100 with an applicator array 102 comprising aplurality of micro-applicators 110. In some aspects of the presentdisclosure, the array plate 100 lies on single plane. In other aspectsof the present disclosure, the array plate 100 does not lie on a singleplane as discussed in greater detail below.

In some aspects of the present disclosure, the array plate 100 with theapplicator array 102 is positioned within a housing 140. Each of themicro-applicators 110 comprises a plurality of apertures 112 throughwhich a material M is ejected such that atomized droplets 3 of thematerial are provided as schematically depicted in FIG. 2B.Particularly, each of the micro-applicators 110 has a micro-applicatorplate 114 with the plurality of apertures 112 extending through themicro-applicator plate 114. Also, each of the micro-applicators 110 mayinclude a transducer 120, a frame 130 and a material inlet 138. Thetransducer 120 is in mechanical communication with the micro-applicatorplate 114 such that activation of the transducer 120 ultrasonicallyvibrates the micro-applicator plate 114 as schematically depicted by thehorizontal (z-direction) double-headed arrows in FIG. 2B. The frame 130includes a back wall 134 and at least one sidewall 132 such that areservoir 136 for containing the material M is provided between the backwall 134 and the micro-applicator plate 114. The inlet 138 is in fluidcommunication with reservoir 136 and the material source 8 (FIG. 1) suchthat the material M can flow from the material source 8, through inlet138 and into reservoir 136.

In operation, material M flows through the inlet 138 into the reservoir136. Surface tension of material M results in material M not flowingthrough the apertures 112 of the micro-applicator plate 114 unlesstransducer 120 is activated and vibrates as schematically depicted inFIG. 2B. That is, when transducer 120 is activated and vibrates,material M is ejected through and/or from the plurality of apertures 112as atomized droplets 3. In some aspects of the present disclosure theatomized droplets 3 have an average droplet diameter between 5micrometers (μm) and 100 μm, for example between 10 μm and 75 μm,between 10 μm and 50 μm, or between 20 μm and 40 μm.

As schematically depicted in FIG. 2B, the atomized droplets 3 travel orpropagate in a direction generally normal to the micro-applicator plate114, i.e., generally parallel to a micro-applicator axis 2. As thematerial M is ejected through and/or from the plurality of apertures 112a stream 7 of atomized droplets 3 is provided by each of the pluralityof apertures 112 and a coating C on the surface(s) s′ of a substrate Sis provided. While FIG. 2B schematically depicts the stream 7 ofatomized droplets 3 propagating on the micro-applicator axis 2, itshould be understood that the atomized droplets 3 propagate diffuselyfrom the plurality of apertures 112 and the stream 7 may be angledrelative to the micro-applicator axis 2. It should also be understoodthat other flow configurations of the material M flowing into and out ofthe reservoir 136 are included in the teachings of the presentdisclosure in addition to material M entering reservoir 136 throughinlet 138 and exiting reservoir 136 through apertures 112.

Referring particularly to FIG. 2C, the micro-applicators 110 arepositioned and aligned on a single plane 152. Also, themicro-applicators 110 are arranged in a plurality of subsets 150 _(n)(n=1, 2, . . . ) such that at least one subset 150 n is individuallyaddressable. For example, FIG. 2C schematically depicts three subsets ofmicro-applicators 110: subset 150 ₁, subset 150 ₂, and subset 150 ₃. Thesubset 150 ₁ includes the three middle micro-applicators 110 shown inFIG. 2C, the subset 150 ₂ includes the two outer micro-applicators 110,and the subset 150 ₃ includes the three micro-applicators 110 on theright hand side (+x-direction) of the array plate 100. As shown in FIG.2C, one subset of micro-applicators (e.g., subset 150 ₃) can include oneor more micro-applicators 110 from other subsets (e.g., subsets 150 ₁and 150 ₂). Further, a subset of the micro-applicators may contain onlyone micro-applicator 110. Also, each of the micro-applicators can be asubset and thereby be individually addressable.

In some aspects of the present disclosure, a controller 122 (FIG. 2A) isincluded and enabled to individually address the at least one subset ofmicro-applicators 110 in the applicator array 102. Particularly, each ofthe micro-applicators 110 has a supply line 160 (FIG. 2C) in fluidcommunication with its reservoir 136 and the material source 8. Also,the controller 122 is configured to communicate with (i.e. address,receive, and send data) the power source 6, material source 8 and the atleast one subset of micro-applicators 110 such that the at least onesubset of micro-applicators 110 is individually addressable (e.g.,switched on/off) at any given time. It should be understood that sincethe controller 122 can individually address the at least one subset ofmicro-applicators 110, different materials may be sprayed on the surfaces′ from each applicator array 102. That is, the controller 122 can beconfigured to control which material M flows into the reservoir(s) ofthe at least one subset of micro-applicators 110 at any given time suchthat a coating C comprising a range of thickness, color, rheology, andthe like on the surface s′ of the substrate S is provided. For example,the coating C in FIG. 2C includes a middle section c₁ formed by thesubset 150 ₁ of micro-applicators 110 with a different thickness,viscosity, color, curing rate, etc., than and an outer section c₂ formedby the subset 150 ₂ of the two outer micro-applicators 110. In thealternative, or in addition to, a first coating or first layer I₁ of thecoating C may be formed from a first material M₁ on the substrate Susing a first subset of micro-applicators (e.g., subset 150 ₁) and asecond coating or second layer I₂ of the coating C may be formed from asecond material M₂ over the first coating I₁ using a second subset ofmicro-applicators (e.g., subset 150 ₂). In some aspects of the presentdisclosure, the second coating 12 is applied or formed on the firstcoating I₁ before the first coating I₁ is fully cured. It should beunderstood that the plurality of micro-applicators 110 can move acrossthe surface S (x and/or y directions) such that the first and secondcoatings I₁, I₂ can be formed continuously across the surface s′ of thesubstrate S using only a subset of micro-applicators 110. Thisversatility decreases the consumption of material, energy, etc., of thepaint spray system 1 over other high volume production environment paintsystems.

While FIGS. 2A through 2C schematically depict the micro-applicators 110positioned on the single plane 152, FIGS. 3A through 3C schematicallydepict the micro-applicators positioned on different planes.Particularly, and with reference to FIGS. 3A and 3B, the array plate 100has two planes 152 ₁ and 152 ₂ arranged parallel but not coplanar toeach other. One subset 150 ₄ of the micro-applicators 110 is positionedand aligned on the plane 152 ₁ and another subset 150 ₅ of themicro-applicators 110 is positioned and aligned on the plane 152 ₂.Accordingly, array plate 100 is faceted and has a stepped configuration.Also, and with reference to FIGS. 3A and 3C, the two planes 152 ₁, 152 ₂of the array plate 100 are arranged non-parallel and nonplanar to eachother. One subset 150 ₄ of the micro-applicators 110 is positioned andaligned on the plane 152 ₁ and another subset 150 ₅ of themicro-applicators 110 is positioned and aligned on the plane 152 ₂.Accordingly, array plate 100 is faceted and has an angled configurationwith the angle not equal to zero degrees.

While planes 152 ₁ and 152 ₂ schematically depicted in FIG. 3C areconvexly angled with respect to each other, it should be understood thatplanes concavely angled with respect to each other are within theteachings of the present disclosure. Also, in some forms of the presentdisclosure the array plate 100 is curved (concave or convex).

Referring now to FIG. 4, a method 200 of controlling application ofmaterial(s) to a substrate includes flowing a material into anultrasonic spray nozzle comprising a plurality of micro-applicators atstep 202 and independently addressing a subset of the plurality ofmicro-applicators at step 204. Independently addressing the subset ofmicro-applicators may include varying a pattern width of atomizeddroplets ejected from the plurality of micro-applicators at step 206;varying a flow rate of atomized droplets ejected from the plurality ofmicro-applicators at step 208; varying an angle that the atomizeddroplets are applied to a surface at step 210; ejecting differentmaterials (e.g., M₁, M₂, M₃, or M_(n) shown in FIG. 1) at step 212, andcombinations thereof. Non-limiting examples of materials ejected at step212 include paint materials with different colors/pigments shown at 214,materials for different coating types (e.g., paint, sealant, adhesive,etc.) shown at 216, different materials for a given coating type (e.g.,a paint basecoat material and a paint clearcoat material) shown at 218;and combinations thereof.

It should be understood from the teaching of the present disclosure thatmethods of controlling application of a material to a vehicle isprovided. The method includes configuring a subset of an array ofmicro-applicators to eject a different material than the remainder ofthe micro-applicators. The different material may be a paint basecoat,paint a clearcoat, a flake containing basecoat, a non-flake containingbasecoat, and the like. As such, the methods may include configuring afirst subset of micro-applicators through which a first material isejected and configuring a second subset of micro-applicators throughwhich a second material is ejected. The first material may be ejectedand applied onto a sag prone area of a vehicle followed by ejecting andapplying the second material onto the sag prone area of the vehicle. Forexample, the first material is a one-component (1K) material and thesecond material is a rheology control agent. The rheology control agentmay be an increased viscosity material or a catalyst material. Couplingthe rheology control agent with the 1K material forms a two-component(2K) material that improves overall appearance and sag control of the 2Kmaterial on the sag prone area of the vehicle.

As described above the controller is enabled to individually address atleast a subset of the micro-applicators. Thus, a plurality ofmicro-applicators through manual or automated control are configured andenabled to control (on/off/intensity): flow rate of material, materialto be applied, number of materials, pattern width, othercoating/painting variables, and combinations thereof. It should beunderstood that controlling material flow rate ejected from theplurality of micro-applicators controls droplet density and controllingdensity based as a function of part geometry enables uniform coverageand improves efficiency.

As described above, the present disclosure enables individuallyaddressable micro-applicators and individually addressable arrays orsubsets of arrays of micro-applicators. In some aspects of the presentdisclosure the individually addressable micro-applicators enableejecting two or more different narrowly distributed atomized dropletsizes. For example, each micro-applicator and/or each subset ofmicro-applicators of a material applicator can eject a differentmaterial with its required or optimal atomized droplet size. In onenon-limiting example, a first subset of micro-applicators of a materialapplicator applies (e.g., sprays) a basecoat material without metallicflake to a first area of a substrate and a second subset ofmicro-applicators of the material applicator applies a basecoat materialwith metallic flake to a second area of the substrate. Also, the firstsubset of micro-applicators ejects the basecoat material withoutmetallic flake as atomized droplets with a first narrowly distributeddroplet size and the second subset of micro-applicators ejects thebasecoat material with metallic flake as atomized droplets with a secondnarrowly distributed droplet size that is different than the firstaverage droplet size. As used herein, the phrase “narrowly distributeddroplet size” refers to a droplet size distribution where greater than90% of atomized droplets ejected from a micro-applicator have a dropletdiameter within +/−10% of a mean droplet size of the atomized dropletsejected from the micro-applicator. In some aspects of the presentdisclosure, the droplet size distribution comprises greater than 95% ofatomized droplets ejected from a micro-applicator having a dropletdiameter within +/−5% of a mean droplet size.

In another non-limiting example, a first subset of micro-applicators ofa material applicator applies a first color material to a first area ofa substrate and a second subset of micro-applicators of the materialapplicator applies a second color material to a second area of thesubstrate. Also, the first subset of micro-applicators ejects the firstcolor material as atomized droplets with a first average droplet sizeand the second subset of micro-applicators ejects the second colormaterial as atomized droplets with a second average droplet size that isdifferent than the first average droplet size. In still anothernon-limiting example, a first subset of micro-applicators of a materialapplicator applies a first layer material to a substrate and a secondsubset of micro-applicators of the material applicator applies a secondlayer material over the first layer material on the substrate. Also, thefirst subset of micro-applicators ejects the first layer material asatomized droplets with a first average droplet size and the secondsubset of micro-applicators ejects the second layer material as atomizeddroplets with a second average droplet size that is different than thefirst average droplet size.

It should also be understood that a paint booth using the compositeultrasonic applicators disclosed herein may provide improved efficiencyand reduced cost. For example, such a paint booth may have:

-   -   airflow reduced from ˜100 ft/min. down to/60 ft/min.;    -   a side-draft booth in automated zones thereby providing a        smaller footprint for the paint booth;    -   reductions in dry-booth material consumption and a reduction or        elimination of wet-booth sludge system;    -   recirculation of air limited only by LEL (lower explosive level)        of solvent;    -   reduction of high pressure water blasting/cleaning of booth        grates;    -   reduced air consumption and associated reduction in energy used        to heat, humidify, and condition booth air;    -   reduced air consumption allowing reductions in abatement        equipment size; and    -   reduction in sludge waste removal and landfill cost.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.

When an element or layer is referred to as being “on,” or “coupled to,”another element or layer, it may be directly on, engaged, connected orcoupled to the other element or layer, or intervening elements or layersmay be present. In contrast, when an element is referred to as beingOther words used to describe the relationship between elements should beinterpreted in like fashion (e.g., “between” versus “directly between,”etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used to describevarious elements, components, regions, layers and/or sections, theseelements, components, regions, layers and/or sections, should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer and/or section, from another element,component, region, layer and/or section. Terms such as “first,”“second,” and other numerical terms when used herein do not imply asequence or order unless clearly indicated by the context. Thus, a firstelement, component, region, layer or section, could be termed a secondelement, component, region, layer or section without departing from theteachings of the example forms. Furthermore, an element, component,region, layer or section may be termed a “second” element, component,region, layer or section, without the need for an element, component,region, layer or section termed a “first” element, component, region,layer or section.

Spacially relative terms, such as “outer,” “below,” “lower,” and thelike, may be used herein for ease of description to describe one elementor feature's relationship to another element(s) or feature(s) asillustrated in the figures. Spatially relative terms may be intended toencompass different orientations of the device in use or operation inaddition to the orientation depicted in the figures. For example, if thedevice in the figures is turned over, elements described as “below” or“beneath” other elements or features would then be oriented “above” theother elements or features. Thus, the example term “below” can encompassboth an orientation of above or below. The device may be otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

Unless otherwise expressly indicated, all numerical values indicatingmechanical/thermal properties, compositional percentages, dimensionsand/or tolerances, or other characteristics are to be understood asmodified by the word “about” or “approximately” in describing the scopeof the present disclosure. This modification is desired for variousreasons including industrial practice, manufacturing technology, andtesting capability.

The terminology used herein is for the purpose of describing particularexample forms only and is not intended to be limiting. The singularforms “a,” “an,” and “the” may be intended to include the plural formsas well, unless the context clearly indicates otherwise. The terms“including,” and “having,” are inclusive and therefore specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. The method steps, processes, andoperations described herein are not to be construed as necessarilyrequiring their performance in the particular order discussed orillustrated, unless specifically identified as an order of performance.It is also to be understood that additional or alternative steps may beemployed.

The description of the disclosure is merely exemplary in nature and,thus, examples that do not depart from the substance of the disclosureare intended to be within the scope of the disclosure. Such examples arenot to be regarded as a departure from the spirit and scope of thedisclosure. The broad teachings of the disclosure can be implemented ina variety of forms. Therefore, while this disclosure includes particularexamples, the true scope of the disclosure should not be so limitedsince other modifications will become apparent upon a study of thedrawings, the specification, and the following claims.

What is claimed is:
 1. A material applicator for controlling applicationof at least one material on a substrate, the material applicatorcomprising: a housing; and an array plate with an applicator arraypositioned within the housing, the applicator array comprising aplurality of micro-applicators, each of the plurality ofmicro-applicators comprising an ultrasonic transducer, a material inlet,a reservoir, and a micro-applicator plate with a plurality of apertures,wherein the micro-applicator plate is in mechanical communication withthe ultrasonic transducer such that at least one material is ejectedthrough the plurality of apertures as atomized droplets when theultrasonic transducer vibrates the micro-applicator plate.
 2. Thematerial applicator according to claim 1, wherein each of the pluralityof micro-applicators further comprises a frame with the reservoirpositioned between the frame and the micro-applicator plate.
 3. Thematerial applicator according to claim 2, wherein the frame comprises aback wall and at least one sidewall.
 4. The material applicatoraccording to claim 3, wherein the reservoir is between the back wall andthe micro-applicator plate.
 5. The material applicator according toclaim 4, wherein the ultrasonic transducer is positioned between theframe and the micro-applicator plate.
 6. The material applicatoraccording to claim 1, wherein at least a subset of the plurality ofmicro-applicators is individually addressable to apply the at least onematerial to the substrate.
 7. The material applicator according to claim6 further comprising a controller configured to individually address theat least a subset of the plurality of micro-applicators.
 8. The materialapplicator according to claim 1, wherein the plurality ofmicro-applicators are aligned on a single plane.
 9. The materialapplicator according to claim 1, wherein the plurality ofmicro-applicators comprises a first subset of micro-applicators arrangedon a first plane and a second subset of micro-applicators arranged on asecond plane parallel to and different to the first plane.
 10. Thematerial applicator according to claim 9 further comprising a controllerconfigured to individually address the first subset of micro-applicatorsand the second subset of micro-applicators.
 11. The material applicatoraccording to claim 1, wherein the plurality of micro-applicatorscomprises a first subset of micro-applicators arranged on a first planeand a second subset of micro-applicators arranged on a second planenon-parallel to the first plane.
 12. The material applicator accordingto claim 11 further comprising a controller configured to individuallyaddress the first subset of micro-applicators and the second subset ofmicro-applicators.
 13. The material applicator according to claim 11further comprising a robotic arm configured to move the plurality ofmicro-applicators across a surface.
 14. A material applicator forcontrolling application of at least one material on a substrate, thematerial applicator comprising: a housing attached to a robotic armconfigured to move the housing across a surface; and an array plate withan applicator array positioned within the housing, the applicator arraycomprising a plurality of micro-applicators, each of the plurality ofmicro-applicators comprising an ultrasonic transducer, a material inlet,a reservoir, and a micro-applicator plate with a plurality of apertures,wherein the micro-applicator plate is in mechanical communication withthe ultrasonic transducer such that at least one material is ejectedthrough the plurality of apertures as atomized droplets when theultrasonic transducer vibrates the micro-applicator plate.
 15. Thematerial applicator according to claim 14, wherein each of the pluralityof micro-applicators further comprises a frame with a back wall and atleast one sidewall, and the reservoir is between the back wall and themicro-applicator plate.
 16. The material applicator according to claim15, wherein the ultrasonic transducer is positioned between the frameand the micro-applicator plate.
 17. The material applicator according toclaim 14, wherein the plurality of micro-applicators comprises a firstsubset of micro-applicators arranged on a first plane and a secondsubset of micro-applicators arranged on a second plane parallel to anddifferent to the first plane.
 18. The material applicator according toclaim 17 further comprising a controller configured to individuallyaddress the first subset of micro-applicators and the second subset ofmicro-applicators.
 19. The material applicator according to claim 14,wherein the plurality of micro-applicators comprises a first subset ofmicro-applicators arranged on a first plane and a second subset ofmicro-applicators arranged on a second plane non-parallel to the firstplane.
 20. The material applicator according to claim 19 furthercomprising a controller configured to individually address the firstsubset of micro-applicators and the second subset of micro-applicators.